EP0766653B1 - Production de fibres minerales - Google Patents

Production de fibres minerales Download PDF

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Publication number
EP0766653B1
EP0766653B1 EP95921821A EP95921821A EP0766653B1 EP 0766653 B1 EP0766653 B1 EP 0766653B1 EP 95921821 A EP95921821 A EP 95921821A EP 95921821 A EP95921821 A EP 95921821A EP 0766653 B1 EP0766653 B1 EP 0766653B1
Authority
EP
European Patent Office
Prior art keywords
melt
briquettes
fibres
amount
foundry sand
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP95921821A
Other languages
German (de)
English (en)
Other versions
EP0766653A1 (fr
Inventor
Lone Moller Sorensen
Soren Lund Jensen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rockwool AS
Original Assignee
Rockwool International AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Rockwool International AS filed Critical Rockwool International AS
Publication of EP0766653A1 publication Critical patent/EP0766653A1/fr
Application granted granted Critical
Publication of EP0766653B1 publication Critical patent/EP0766653B1/fr
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/002—Use of waste materials, e.g. slags
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B1/00—Preparing the batches
    • C03B1/02—Compacting the glass batches, e.g. pelletising
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/02—Pretreated ingredients
    • C03C1/026—Pelletisation or prereacting of powdered raw materials
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool

Definitions

  • This invention relates to the production of Man Made Vitreous Fibres (MMVF) that are biologically soluble, that is to say they have an acceptable rate of biologically useful degradation in physiological saline solution.
  • MMVF Man Made Vitreous Fibres
  • the mineral melt is generally formed from a blend of minerals selected so that they produce a melt having the desired melting point and other properties, having regard to the intended end use.
  • the mineral materials are usually freshly produced or mined materials such as crushed rock or crushed slag and sand.
  • EP-A-508589 it is proposed to form a melt from a plurality of solid waste streams that are used in proportions such that the melt has a content within certain defined ranges.
  • Materials that are mentioned for use as this plurality of waste streams are municipal incinerator bottom ash, hazardous wastes incinerator bottom ash, baghouse or precipitator dust, steel plant dust, electroplating sludge, electrochemical machining sludge, waste foundry sands, contaminated soils, dried and contaminated sewage solids, cementitious fixation, coal combustion fly ash, inorganic paint pigment residues and spent refractory materials.
  • the furnace can be a coke-fired cupola furnace of the type used in the grey iron casting industry. The melt is drained from the furnace under conditions that allow separation of free metal from the solution of oxides, which can be poured into moulds or quenched.
  • JP-A-55 140 725 a melted blend of steel-making slag and one or more of mine slime, waste enamel and waste molding sand is converted into fibres by dropping.
  • the composition of the fibres influences their properties. It is known that the solubility of MMV fibres in physiological saline solutions can be increased by appropriate selection of the composition of the melt. As a generality, best results are obtained when the amount of aluminium in the melt, measured as oxides, is below 3 or 4% by weight Al 2 O 3 . Accordingly, if biological solubility is required the mineral material for forming the briquettes, and any additional material that is included in the charge, has to be selected so that it complies both with the required low aluminium content and with the requirement that the melt has appropriate melt properties. Thus the charge must have appropriate melting temperature and viscosity characteristics such that the melt has appropriate fibre-forming properties.
  • Mineral fibres are generally made by a process comprising forming moulded briquettes of particulate mineral material, forming a melt by melting in a furnace a mineral charge comprising such briquettes and forming fibres from the melt.
  • the components of the mineral charge have to be selected so as to provide a melt having appropriate melt properties and fibre-forming properties and this places constraints on the materials that can be used.
  • the melt should have a low alumina content, this imposes further constraints on the choice of materials for the mineral charge.
  • Materials that have low alumina content and that might be thought to be suitable tend to be rather expensive and some of these materials tend to provide a melt having inconvenient melt properties, for instance a rather high melting point. In practice therefore it is necessary to use very expensive blends of materials for forming biologically soluble MMV fibres, and this represents a serious impediment to the availability of such fibres.
  • MMV fibres are made by a method comprising forming moulded briquettes of particulate mineral material, forming a melt by melting in a furnace a mineral charge comprising the briquettes and forming fibres from the melt, and in this method the melt and the fibres have a content, measured as oxides, that includes alumina in an amount of up to 4% by weight and the briquettes are formed of particulate mineral material that includes contaminated foundry sand.
  • contaminated foundry sand is foundry sand that has been used for making a foundry mould and that is still contaminated with a substantial proportion of the impurities that are present in the foundry sand after its use as a foundry mould.
  • binder such as phenol formaldehyde resin, furan, bentonite or other foundry binder, and often with residues of metal, from the casting operation.
  • the presence of these various residues has resulted in it generally being considered that the foundry sand cannot be used for any useful process unless it is first subjected to thermo/mechanical regeneration process comprising the steps of crushing, sieving, washing and incinerating to remove the contaminants and fines.
  • the contaminated foundry sand is used without significant prior reclamation processes. Indeed, if any reclamation process is conducted, it is usually confined to sieving the sand.
  • the invention simultaneously solves two problems, namely the need to find a way of economically utilising contaminated foundry sand, and the need to find a cost-effective mineral that can be used in a fibre-forming melt designed to produce fibres having low alumina content.
  • One advantage of the invention lies in the fact that it is not necessary to remove fines from the contaminated foundry sand before it may be used. As explained above, this was previously always considered necessary if the foundry sand was to be useful. Thus particularly economical use of contaminated foundry sand is made possible by the invention.
  • fines exhibit excellent melting properties in conventionally used melting processes. This is due to their need for shorter residence times at any given melting temperature than larger particle size foundry sand.
  • the amount of contaminated foundry sand is preferably at least 10%, usually at least 20% based on the total mineral charge and often at least 30%. Usually it is not more than 75%, and generally it is in the range 20 to 40 or 45% by weight of the total mineral charge.
  • the melt will generally have a content of CaO in the range 10 to 40% and a content of MgO in the range 5 to 30% (often 7 to 20%). Generally the total amount of CaO plus alkali is 10 to 48% and the total amount of MgO + FeO is in the range 7 to 30%. The amount of SiO 2 is generally in the range 35 to 75%.
  • the blend is such that the total alumina content is below 3% and often below 1%.
  • the blend can contain various compounds additional to the alumina, CaO, MgO, alkali and FeO and SiO 2 contents mentioned above. Thus it may contain other elements such as phosphorous, boron and titanium, generally each in an amount of not more than 10% measured as oxide.
  • substantially each briquette should have a content of Al 2 O 3 of 0 to 4%, MgO 5 to 30% and CaO of 5 to 40%, all based on the weight of the briquette.
  • the desired chemical content may be achieved merely by mixing silica sand with olivine sand and a source of CaO, wherein generally all the sand is contaminated foundry sand but some could be uncontaminated sand.
  • the briquettes are formed from a blend of one or more contaminated foundry sands with other inorganic material, which may itself be industrial waste material.
  • Suitable industrial waste materials include converter slag, glass, asbestos-free fibre cement, wood ash and steel plant dust and MMV fibre products, for instance bonded MMV fibrous material. This fibrous material may be recycled from the process or may be waste, previously manufactured, material.
  • the charge to the furnace may consist solely of the briquettes containing contaminated foundry sand or, more usually, is a mixture of at least 30%, often at least 50% and typically up to 80% or more, of such briquettes with other particulate material.
  • This other material may comprise briquettes made from materials free of contaminated foundry sand and/or other mineral material suitable for incorporation in the melt.
  • This additional mineral material may be industrial waste, as discussed above, or may be virgin mineral material that has not previously been used.
  • Such mineral material that can be used as part of the non-briquette charge or as components in briquettes, can include materials such as dolomite, iron ore, limestone, rutile, magnesite, magnetite, brucite, burnt lime, slag and other materials suitable for forming a fibre-forming melt.
  • the blend of contaminated foundry sand, other industrial waste and other mineral material should be such that the melt and the fibres have the desired composition.
  • the briquettes may be made by any suitable method. Generally they are made by bonding inorganic material using a binder, often associated with compression.
  • the binder can be a hydraulic binder such as cement or may be a slag activated with an alkaline agent, as in W092/04289.
  • the binder may alternatively be a burnt lime which is hydrated on heating in the presence of water-the well known lime/sandstone process.
  • the binder may be an organic binder, for instance a lignin binder obtained by mixing calcium lignosulphonate with the particulate material in the presence of water, allowing curing to start and then subjecting the partially cured mix to compression moulding, for instance on a roller moulding machine.
  • organic binder is advantageous as it avoids the introduction of alumina or other inorganic component that might place an additional constraint on the materials that can be used in the charge.
  • the briquettes may have conventional dimensions, for instance a minimum dimension of at least 5mm, often at least 20mm and usually at least 40mm and a maximum dimension of up to 300mm but usually not more than around 150 or 200mm.
  • the furnace may be heated in conventional manner, for instance as an electrical furnace or a tank furnace or, more usually by combustion of combustible material in a cupola furnace.
  • the melt temperature will depend upon the minerals being used and the fibre-forming technique but is generally in the range 1200 to 1600°C, often around 1400 to 1550°C.
  • Fibre formation can be by conventional techniques such as a spinning cup technique or, preferably, by pouring on to a spinner comprising at least two co-operating spinning wheels, for instance as described in WO92/06047.
  • the fibres may be made by pouring the melt on to a first spinning rotor from which the melt is thrown in sequence on to one or more subsequent spinning rotors off which the fibres are thrown.
  • the products of the invention can be used for any of the conventional uses of MMV fibres, such as thermal insulation, noise reduction and regulation, fire protection, growth media, reinforcement and fillers.

Claims (9)

  1. Procédé de formation de fibres vitreuses artificielles comprenant la formation de briquettes moulées de matière minérale particulaire, la formation d'une masse fondue par fusion dans un four d'une charge comprenant les briquettes et la formation de fibres à partir de la masse fondue, caractérisé en ce que la masse fondue et les fibres ont une teneur, mesurée en oxydes, qui comprend Al2O3 en une quantité d'au plus 4% en masse et les briquettes sont formées de matière particulaire qui comprend du sable de fonderie contaminé.
  2. Procédé selon la revendication 1, dans lequel les briquettes sont formées de matière particulaire qui comprend du sable de fonderie contaminé en une quantité d'au moins 10 % en masse par rapport à la charge minérale totale.
  3. Procédé selon la revendication 1 ou la revendication 2, dans lequel la quantité de sable de fonderie contaminé dans les briquettes est de 10 à 70 % par rapport à la masse de la charge minérale totale.
  4. Procédé selon l'une quelconque des revendications précédentes, dans lequel sensiblement chacune des briquettes a une teneur en MgO de 5 à 30 % et une teneur en CaO de 5 à 40 % en masse.
  5. Procédé selon l'une quelconque des revendications précédentes, dans lequel la masse fondue et les fibres ont une teneur qui comprend 0 à 4 % de Al2O3, 10 à 40 % de CaO, 5 à 30 % de MgO et 25 à 75 % de SiO2, et d'autres oxydes chacun en une quantité d'au plus 20 %.
  6. Procédé selon la revendication 5, dans lequel la quantité de CaO plus alcali est de 10 à 48 % et la quantité de MgO + FeO est de 7 à 30 %.
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel les briquettes sont formées en outre d'autres déchets industriels choisis parmi les scories de convertisseur, le verre, le ciment de fibres sans amiante, la cendre de bois, la poussière d'aciérie et des produits fibreux vitreux artificiels, où la quantité totale de sable de fonderie contaminé et d'autres déchets industriels est d'au moins 50 % par rapport à la charge minérale totale.
  8. Procédé selon l'une quelconque des revendications précédentes, dans lequel le four est un cubilot.
  9. Procédé selon l'une quelconque des revendications précédentes, dans lequel les fibres sont produites par déversement de la masse fondue sur un premier rotor en rotation depuis lequel la masse fondue et projetée successivement sur un ou plusieurs rotors en rotation subséquents depuis lesquels les fibres sont projetées.
EP95921821A 1994-06-15 1995-06-02 Production de fibres minerales Revoked EP0766653B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB9412011A GB9412011D0 (en) 1994-06-15 1994-06-15 Production of mineral fibres
GB9412011 1994-06-15
PCT/EP1995/002109 WO1995034516A1 (fr) 1994-06-15 1995-06-02 Production de fibres minerales

Publications (2)

Publication Number Publication Date
EP0766653A1 EP0766653A1 (fr) 1997-04-09
EP0766653B1 true EP0766653B1 (fr) 1998-12-23

Family

ID=10756779

Family Applications (1)

Application Number Title Priority Date Filing Date
EP95921821A Revoked EP0766653B1 (fr) 1994-06-15 1995-06-02 Production de fibres minerales

Country Status (13)

Country Link
EP (1) EP0766653B1 (fr)
AT (1) ATE174881T1 (fr)
AU (1) AU2674095A (fr)
CA (1) CA2192966A1 (fr)
CZ (1) CZ364296A3 (fr)
DE (1) DE69506870T2 (fr)
ES (1) ES2125622T3 (fr)
FI (1) FI964953A (fr)
GB (1) GB9412011D0 (fr)
HU (1) HU221101B1 (fr)
PL (1) PL317858A1 (fr)
SK (1) SK280605B6 (fr)
WO (1) WO1995034516A1 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE1010725A3 (nl) * 1996-10-30 1998-12-01 Calumite Company Europ Naamloz Werkwijze voor het valoriseren en het eventueel daartoe bewerken van potslakken.
UA74802C2 (en) * 1999-12-06 2006-02-15 Rgs90 A process for producing glass, glass produced by this method and use thereof
FI110607B (fi) * 2000-06-20 2003-02-28 Paroc Group Oy Ab Menetelmä briketin ja mineraalivillan valmistamiseksi
DE10337087B4 (de) * 2003-08-12 2006-12-14 Saint-Gobain Isover G+H Ag Verfahren zur Erzeugung eines Granulates aus Altglas und Verwendung
CN103102057B (zh) * 2013-02-07 2015-07-29 燕山大学 自粘结和预分解的玻璃配合料的制备方法
CN109748494A (zh) * 2019-03-05 2019-05-14 沈阳化工大学 一种利用废耐火材料废树脂砂和硼泥制备硅酸铝棉方法

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS55140725A (en) * 1979-04-19 1980-11-04 Hiyougoken Manufacture of slag wool using steel making slag as starting material
FI86541C (sv) * 1990-08-29 1992-09-10 Partek Ab Råmaterialbrikett för mineralullstillverkning och förfarande för dess framställning

Also Published As

Publication number Publication date
DE69506870T2 (de) 1999-05-27
ATE174881T1 (de) 1999-01-15
HUT75976A (en) 1997-05-28
WO1995034516A1 (fr) 1995-12-21
HU9603445D0 (en) 1997-02-28
FI964953A0 (fi) 1996-12-11
AU2674095A (en) 1996-01-05
CZ364296A3 (cs) 1998-03-18
EP0766653A1 (fr) 1997-04-09
SK160496A3 (en) 1997-08-06
DE69506870D1 (de) 1999-02-04
FI964953A (fi) 1997-02-06
ES2125622T3 (es) 1999-03-01
GB9412011D0 (en) 1994-08-03
HU221101B1 (en) 2002-08-28
CA2192966A1 (fr) 1995-12-21
PL317858A1 (en) 1997-04-28
SK280605B6 (sk) 2000-05-16

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